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AI Drone Infrastructure Inspection

AI Drone Infrastructure Inspection for Oil and Gas

Ombrulla implemented an AI Drone Infrastructure Inspection workflow for oil and gas asset integrity teams. Drone flights capture high-resolution video of critical infrastructure such as storage tanks and pipelines. Ombrulla’s AI models analyze the footage to detect and classify anomalies including cracks, corrosion, paint/coating loss, insulation damage, and potential leaks.

Drone capturing video of oil and gas storage tanks for AI inspection.
Executive Summary

AI Overview Summary

Ombrulla deployed an AI-powered drone inspection workflow to support oil and gas asset integrity teams in monitoring critical infrastructure more efficiently and safely. High-resolution drone video is captured across assets such as storage tanks, pipelines, and associated facilities, then analyzed by Ombrulla’s AI models to detect and classify anomalies including cracks, corrosion, coating loss, insulation damage, and potential leaks. This enables a faster, safer, and more consistent inspection process with traceable visual evidence, helping teams intervene earlier and prioritize maintenance more effectively.

  • Process: Infrastructure inspection for oil and gas assets (tanks, pipelines, and associated facilities)
  • Data source: Drone video (visible spectrum; thermal optional based on use case)
  • Anomalies detected: Cracks, corrosion, coating/paint removal, insulation damage, leaks and seepage indicators
  • Typical deployment: Pre-planned drone missions + AI analysis + exception review + maintenance work order integration
  • Primary outcomes: Reduced inspection risk and downtime, faster anomaly identification, audit-ready evidence, improved integrity governance

Business Context

Routine and event-driven visual inspection of critical infrastructure - storage tanks, pipelines, and other facilities - using drone data as the primary capture method.

  • -Safety and HSE: Reduce work at height, rope access, scaffolding, and exposure time in hazardous zones.
  • -Risk reduction: Detect early-stage degradation before it escalates into leaks, unplanned shutdowns, or reportable incidents.
  • -Cost and uptime: Shift from reactive repairs to targeted maintenance planning and fewer emergency interventions.
  • -Governance: Provide traceable visual evidence to support integrity programs, audits, and contractor accountability.

The Challenge

Traditional infrastructure inspections in oil and gas often depend on manual walkdowns, rope access teams, scaffolding, and periodic shutdown windows. Even when drones are used, the bottleneck frequently shifts to manual video review.

  • Slow Review Cycles

    Large volumes of video/images take hours or days to analyze and report.

  • Coverage Constraints

    High or confined areas may be sampled rather than fully reviewed due to access limits.

  • Inconsistent Interpretation

    Defect identification varies by reviewer experience and fatigue.

  • Evidence Gaps

    Findings may lack precise location mapping, making reinspection and follow-up slower.

Deferred risk: Minor corrosion, coating failures, or insulation damage can progress between inspection rounds.

The Solution

Ombrulla introduced an AI-driven inspection layer on top of drone capture. Drone missions collect consistent, repeatable video of asset surfaces and components. Ombrulla’s anomaly detection models automatically scan the footage, flagging potential issues and producing a structured inspection output.

AI dashboard view showing detected anomalies with bounding boxes.

The system provides an asset map / digital twin view linking findings to exact locations (tank courses, nozzle zones, pipeline chainage).

How It Works

Mission planning icon

1. Mission Planning

Define inspection scope by asset type and risk priority. Plan flight paths for repeatable coverage (angles, standoff distance, overlap).

Drone capture icon

2. Drone Capture

Capture high-resolution video; use thermal payloads where leak/heat anomalies are relevant.

AI analysis icon

3. AI Anomaly Detection

Models analyze video frames to detect and segment defects like cracks and corrosion. Findings are categorised and scored.

Exception workflow icon

4. Exception Workflow

Integrity engineer reviews flagged anomalies (human-in-the-loop) and confirms true positives.

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5. Maintenance Action

Confirmed findings are generated as inspection records and routed into SAP/CMMS as work orders.

Measurable Impact

Core value delivered by the drone-video inspection approach.

  • 70% to 100% less high-risk exposure

    Reduce the need for manual access in elevated, remote, and hazardous inspection environments.

  • 50% to 75% faster inspection turnaround

    Move from drone capture to reviewed findings and maintenance action in significantly less time.

  • 100% standardized inspection logic

    Apply a consistent defect taxonomy and reporting structure across sites and contractors.

  • Top 10% to 20% of anomalies prioritized first

    Help maintenance teams focus on the issues with the highest operational and asset risk.

  • Fully traceable inspection evidence

    Maintain a digital record from captured image to reviewed anomaly to follow-up action.

  • 2x to 4x greater inspection coverage

    Scale inspection programs across more assets and locations without linear growth in review effort.

Defects and anomalies detected

Our AI models are designed to detect and classify a wide range of visual integrity issues across industrial infrastructure, helping inspection teams identify risks earlier, prioritize maintenance more effectively, and improve reporting consistency.

Corrosion

Detects visible corrosion, rust, and pitting that indicate early material degradation.

Corrosion icon

Cracks and Fractures

Identifies cracks, fractures, and surface splits that may signal structural stress or damage.

Cracks and fractures icon

Coating and Paint Failure

Recognizes coating breakdown such as peeling, blistering, and bare-metal exposure.

Coating and paint failure icon

Leakage and Seepage Indicators

Flags visual signs of leaks, including stains, drips, wet patches, and residue trails.

Leakage and seepage icon

Insulation and Cladding Damage

Detects damaged insulation, broken cladding, and exposed areas linked to thermal loss or CUI risk.

Insulation and cladding damage icon

Infrastructure in Scope

Drones and AI video analytics help inspect critical industrial assets such as storage tanks, pipelines, process units, and substations. They improve inspection accuracy, asset monitoring, and maintenance planning.

  • -Storage tanks – shell, roof, nozzles, stairways, and bund walls.
  • -Pipelines and pipe racks – supports, expansion loops, crossings, and ROW monitoring.
  • -Process units – equipment and structures within operating process areas.
  • -Other critical infrastructure – flare stacks, chimneys, jetties, and substations.

Implementation Approach

A typical production-grade rollout phases:

  • -Asset register mapping: Define assets, zones, and priorities.
  • -Data capture standardisation: Flight plans and image quality guidelines.
  • -Model configuration: Taxonomy and severity rules.
  • -Pilot run: Parallel manual + AI review to calibrate thresholds.
  • -Go-live: SOP updates, training, and integration.

KPIs to Track Post Go-Live

  • -Inspection turnaround time (capture-to-report).
  • -High-risk access hours avoided.
  • -Anomaly detection precision and confirmation rate.
  • -Mean time to repair (MTTR) for critical anomalies.
  • -Repeat anomaly rate by asset.

Frequently Asked Questions